Apparatus and associated methods relate to dynamically generating commands to manage the flow rate of a powder as a function of time in response to arbitrarily shaped target parts traveling along a conveyor. In an illustrative example, a controller may receive shape information about each target part as the part travels along the conveyor. The controller may dynamically generate commands to a pump to control the flow rate of powder to a reciprocating nozzle. In some embodiments, the controller may generate motion trajectory commands to the reciprocating nozzle to deliver a predetermined amount of powder to the target part as the target part travels along the conveyor.
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1. A powder dispersing management system comprising: a controller; a sensor interface operably coupled to the controller and configured to receive shape information measured by a sensor as a target object is being conveyed along a path of travel of a conveyor, the shape information defining a shape profile of the target object in a dimension orthogonal to the conveyor path of travel; a dispersing command output interface operably coupled to the controller and adapted to convey a powder dispersing command to a powder flow controller that supplies powder to a reciprocating nozzle; a nozzle motion trajectory command interface operably coupled to the controller and adapted to convey nozzle motion trajectory commands to a position controller for the reciprocating nozzle; a non-volatile memory operably coupled to the controller and containing a program of instructions that, when executed by the controller, cause the controller to perform operations to dispense a predetermined amount of powder in response to the shape information of the target object, the operations comprising: dynamically generate a nozzle temporal profile comprising a coordinated set of nozzle motion trajectory commands and powder dispersing commands based on the received shape information; transmit the powder dispersing commands to the powder flow controller via the dispersing command output interface; and, transmit the nozzle temporal profile to the position controller via the nozzle motion trajectory command interface; wherein the nozzle temporal profile is generated such that a predetermined amount of powder is dynamically supplied to the target object based on the shape of a portion of the target object as it passes by the nozzle.
A powder dispersing system manages powder flow to a target moving on a conveyor. It uses a controller connected to: a sensor interface that receives shape data of the target from a sensor (shape is measured perpendicular to the conveyor); a dispersing command output to control powder flow to a reciprocating nozzle; and a nozzle motion command output to control the nozzle's position. The controller uses stored instructions to analyze the target's shape and generate a coordinated set of commands for both powder flow and nozzle movement, sending these commands to their respective controllers. This ensures the correct amount of powder is applied to each part of the target as it moves past the nozzle.
2. The apparatus of claim 1 , wherein the target object is a wood part.
The powder dispersing system described previously, which manages powder flow to a target moving on a conveyor using shape data and coordinated nozzle control, is specifically used where the target object being coated with powder is a wood part.
3. The apparatus of claim 1 , wherein the target object is a metal part.
The powder dispersing system described previously, which manages powder flow to a target moving on a conveyor using shape data and coordinated nozzle control, is specifically used where the target object being coated with powder is a metal part.
4. The apparatus of claim 1 , wherein the sensor is a photoelectric light screen.
The powder dispersing system described previously, which manages powder flow to a target moving on a conveyor using shape data and coordinated nozzle control, incorporates a photoelectric light screen as the sensor used to capture the shape data of the target object.
5. The apparatus of claim 1 , wherein the sensor is a laser break-beam sensor.
The powder dispersing system described previously, which manages powder flow to a target moving on a conveyor using shape data and coordinated nozzle control, incorporates a laser break-beam sensor as the sensor used to capture the shape data of the target object.
6. The apparatus of claim 1 , further comprising the sensor interface operably connected to a hygrometer and configured to receive humidity measurements from the hygrometer, wherein the sensor interface transmits the humidity measurements to the controller.
The powder dispersing system described previously, which manages powder flow to a target moving on a conveyor using shape data and coordinated nozzle control, adds a hygrometer connected to the sensor interface. The system now receives humidity readings alongside the target's shape, sending this humidity data to the controller for use in powder application adjustments.
7. The apparatus of claim 6 , the operations further comprising generate an adjustment humidity variable based on the received humidity measurements.
In the powder dispersing system that includes a hygrometer to measure humidity, the controller uses those humidity measurements to calculate an "adjustment humidity variable". This variable represents the effect of humidity on the powder application process.
8. The apparatus of claim 7 , the operations further comprising generate a nozzle temporal profile comprising a coordinated set of nozzle motion trajectory commands and powder dispersing commands, based on the received shape information, and adjusted to account for the adjustment humidity variable.
The powder dispensing system, having a humidity sensor to make adjustments to the powder coating, incorporates the "adjustment humidity variable" into generating the commands for powder flow and nozzle movement. This allows the system to compensate for changes in humidity and maintain a consistent powder coating thickness. The nozzle temporal profile will therefore be dynamically generated to account for humidity.
9. The apparatus of claim 1 , further comprising a network interface card configured to communicate with a remote database.
The powder dispersing system described previously, which manages powder flow to a target moving on a conveyor using shape data and coordinated nozzle control, includes a network interface card. This card enables the system to communicate with a remote database, allowing for data exchange and remote monitoring/control.
10. The apparatus of claim 9 , wherein the remote database stores the received shape information.
The powder dispersing system that connects to a remote database uses that database to store the shape information collected about the target objects. This allows for analysis of trends, quality control, and optimization of the powder coating process.
11. A powder dispersing management system comprising: a controller; a sensor interface operably coupled to the controller and configured to receive shape information measured by a sensor as a target object is being conveyed along a path of travel of a conveyor, the shape information defining a shape profile of the target object in a dimension orthogonal to the conveyor path of travel; a dispersing command output interface operably coupled to the controller and adapted to convey a powder dispersing command to a powder flow controller that supplies powder to a reciprocating nozzle; a nozzle motion trajectory command interface operably coupled to the controller and adapted to convey nozzle motion trajectory commands to a position controller for the reciprocating nozzle; a non-volatile memory operably coupled to the controller and containing a program of instructions that, when executed by the controller, cause the controller to perform operations to dispense a predetermined amount of powder in response to the shape information of the target object, the operations comprising: generating a nozzle temporal profile comprising a coordinated set of nozzle motion trajectory commands and powder dispersing commands based on the received shape information; transmitting the powder dispersing commands to the powder flow controller via the dispersing command output interface; and, transmitting the nozzle temporal profile to the position controller via the nozzle motion trajectory command interface; wherein the nozzle temporal profile is generated such that a predetermined amount of powder is dynamically supplied to the target object based on the shape of a portion of the target object as it passes by the nozzle.
A powder dispersing system manages powder flow to a target moving on a conveyor. It uses a controller connected to: a sensor interface that receives shape data of the target from a sensor (shape is measured perpendicular to the conveyor); a dispersing command output to control powder flow to a reciprocating nozzle; and a nozzle motion command output to control the nozzle's position. The controller uses stored instructions to analyze the target's shape and generate a coordinated set of commands for both powder flow and nozzle movement, sending these commands to their respective controllers. This ensures the correct amount of powder is applied to each part of the target as it moves past the nozzle.
12. The apparatus of claim 11 , wherein the target object is a wood part.
The powder dispersing system described previously, which manages powder flow to a target moving on a conveyor using shape data and coordinated nozzle control, is specifically used where the target object being coated with powder is a wood part.
13. The apparatus of claim 11 , wherein the target object is a metal part.
The powder dispersing system described previously, which manages powder flow to a target moving on a conveyor using shape data and coordinated nozzle control, is specifically used where the target object being coated with powder is a metal part.
14. The apparatus of claim 11 , wherein the sensor is a photoelectric light screen.
The powder dispersing system described previously, which manages powder flow to a target moving on a conveyor using shape data and coordinated nozzle control, incorporates a photoelectric light screen as the sensor used to capture the shape data of the target object.
15. The apparatus of claim 11 , wherein the sensor is a laser break-beam sensor.
The powder dispersing system described previously, which manages powder flow to a target moving on a conveyor using shape data and coordinated nozzle control, incorporates a laser break-beam sensor as the sensor used to capture the shape data of the target object.
16. The apparatus of claim 11 , further comprising the sensor interface operably connected to a hygrometer and configured to receive humidity measurements from the hygrometer, wherein the sensor interface transmits the humidity measurements to the controller.
The powder dispersing system described previously, which manages powder flow to a target moving on a conveyor using shape data and coordinated nozzle control, adds a hygrometer connected to the sensor interface. The system now receives humidity readings alongside the target's shape, sending this humidity data to the controller for use in powder application adjustments.
17. A powder dispersing management system comprising: a controller; a sensor interface operably coupled to the controller and configured to receive shape information measured by a sensor as a target object is being conveyed along a path of travel of a conveyor, the shape information defining a shape profile of the target object in a dimension orthogonal to the conveyor path of travel; a dispersing command output interface operably coupled to the controller and adapted to convey a powder dispersing command to a powder flow controller that supplies powder to a reciprocating nozzle; a non-volatile memory operably coupled to the controller and containing a program of instructions that, when executed by the controller, cause the controller to perform operations to dispense a predetermined amount of powder in response to the shape information of the target object, the operations comprising: dynamically generate a nozzle temporal profile comprising the powder dispersing commands based on the received shape information; transmit the powder dispersing commands to the powder flow controller via the dispersing command output interface; and, wherein the nozzle temporal profile is generated such that a predetermined amount of powder is dynamically supplied to the target object based on the shape of a portion of the target object as it passes by the nozzle.
A powder dispersing system manages powder flow to a target moving on a conveyor. It uses a controller connected to: a sensor interface that receives shape data of the target from a sensor (shape is measured perpendicular to the conveyor); and a dispersing command output to control powder flow to a reciprocating nozzle. The controller uses stored instructions to analyze the target's shape and generate powder flow commands, sending these commands to the powder flow controller. This ensures the correct amount of powder is applied to each part of the target as it moves past the nozzle.
18. The apparatus of claim 17 , further comprising a nozzle motion trajectory command interface operably coupled to the controller and adapted to convey nozzle motion trajectory commands to a position controller for the reciprocating nozzle.
The powder dispersing system that controls the powder flow to a reciprocating nozzle, adds a nozzle motion command output to control the nozzle's position. The controller is also connected to a position controller for the reciprocating nozzle.
19. The apparatus of claim 18 , the operations further comprising transmit the nozzle temporal profile to the position controller via the nozzle motion trajectory command interface.
The powder dispersing system, having control of both powder flow and nozzle position, transmits a nozzle temporal profile to the position controller. This profile dictates how the nozzle moves and dispenses powder over time.
20. The apparatus of claim 17 , wherein the target object is a wood part.
The powder dispersing system described previously, which manages powder flow to a target moving on a conveyor using shape data, is specifically used where the target object being coated with powder is a wood part.
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March 8, 2016
April 25, 2017
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